Download of .zip file runs a corrupted file php

I bet two beers that a PHP error occurs, and the error message messes up the ZIP file. The requested file probably doesn't exist.

Open the ZIP file with notepad or a similar text editor, and find out what's wrong.

This issue can have several causes. Maybe your file is not found or it can not be read and thus the file’s content is just the PHP error message. Or the HTTP header is already sent. Or you have some additional output that then corrupts your file’s content.

Try to add some error handling into your script like this:

$file='../downloads/'.$filename;
if (headers_sent()) {
    echo 'HTTP header already sent';
} else {
    if (!is_file($file)) {
        header($_SERVER['SERVER_PROTOCOL'].' 404 Not Found');
        echo 'File not found';
    } else if (!is_readable($file)) {
        header($_SERVER['SERVER_PROTOCOL'].' 403 Forbidden');
        echo 'File not readable';
    } else {
        header($_SERVER['SERVER_PROTOCOL'].' 200 OK');
        header("Content-Type: application/zip");
        header("Content-Transfer-Encoding: Binary");
        header("Content-Length: ".filesize($file));
        header("Content-Disposition: attachment; filename=\"".basename($file)."\"");
        readfile($file);
        exit;
    }
}